Automating Paper Waste Collection in a High-Security Financial Facility

Summary

A high-security credit card production facility needed to automate its labor-intensive paper waste process across three 24/7 printing stations. Glacier Technology installed a Eurovac central vacuum system paired with a Plattco Double Dump Valve to prevent jamming of the facility’s long, narrow paper scraps. The new system eliminated manual waste handling, improved cleanliness, increased uptime, and ensured reliable, around-the-clock performance without disrupting production.

Background: A 24/7 Facility With Unique Security and Production Demands

One of the nation’s leading producers of credit cards and credit-card documentation operates a highly secure, 24/7 printing and inserting facility. With nonstop production and tight security protocols similar to entering an airport, the facility must maintain absolute control over material flow, traceability, waste handling, and uptime.

During the printing and document-insertion process, the plant generates a significant volume of small paper trim pieces, approximately 1” x 4” each. Although the plant already recycled the waste, the previous collection process required extensive manual labor at each workstation. Operators had to stop production every 30 minutes to empty the waste bins, clean around equipment, and ensure the paper waste was properly handled. As volume increased, this approach became inefficient, time-consuming, and a potential bottleneck in a tightly controlled workflow.

The Challenge: Automating Waste Collection Without Creating Downtime

The client wanted a way to:

• Remove hand labor from the paper waste process
• Keep three production workstations clean and operational around the clock
• Prevent paper scraps from clogging equipment
• Collect waste safely in a sealed container that aligns with their security and recycling protocol

The biggest engineering challenge was the waste itself. The 1” x 4” paper pieces are long enough to bridge and jam inside a typical rotary airlock. This risk made traditional airlocks unsuitable.

Glacier Technology needed to develop a system that could:

• Run 24/7
• Maintain consistent high vacuum
• Keep airflow sealed and controlled
• Avoid jamming, even with problematic waste geometry
• Integrate cleanly into a high-security environment without disrupting production

The Solution: A Eurovac Central Vacuum System With a Plattco Double Dump Valve

To eliminate manual handling and automate the collection process, Glacier Technology supplied and installed a Eurovac central vacuum system designed specifically for continuous-duty industrial waste capture.

Why Eurovac

Eurovac systems provide:

• Industrial-grade vacuum producers designed for 24/7 uptime
• Superior filtration for consistent high-vacuum performance
• Engineered layouts tailored to customer workflow
• Reliable operation with minimal maintenance
• Clean integration into multi-source collection systems

All three printing workstations were ducted into a single Eurovac system. Now, instead of operators emptying individual bins, paper waste is automatically conveyed into a central discharge location. The vacuum system is 200 feet away from the production area. We added a bin level sensor to the collector, but also a warning light out in the production area to alert staff when the bin is nearing full.  

Solving the Biggest Obstacle: Paper Waste Jamming

Because the 1” x 4” scrap pieces posed a jamming risk in rotary airlocks, Glacier recommended and installed a Plattco Double Dump Valve (also known as a double flap gate or double airlock).

This valve design:

• Moves material in discrete batches rather than relying on rotating blades
• Prevents bridging, binding, and jamming
• Provides an extremely reliable airlock seal
• Eliminates fugitive air that could compromise system performance
• Ensures smooth drop-out of waste into the Gaylord container below

Plattco’s Double Flap Airlock® Valve technology, trusted for more than 60 years, proved the ideal choice for handling irregular paper scrap while keeping the vacuum system sealed and efficient. 

Results: From Manual Labor to a Fully Automated Waste Stream

The installation transformed the client’s workflow:

• Manual disposal eliminated at all three stations
• Cleaner, safer work areas without the mess of overflowing bins
• Reduced operator downtime, with fewer interruptions to production
• Reliable 24/7 performance, thanks to Eurovac’s industrial vacuum platform
• No jamming or system slowdowns, thanks to the Plattco double dump valve
• Fully sealed and controlled discharge, aligning with the facility’s security protocols

The automated Eurovac waste system now supports continuous production without adding labor burden, exactly what a high-security, high-throughput environment needs.

Engineered vacuum collection offers significant benefits for facilities facing labor-intensive material handling challenges.

For plants running around the clock, even small bottlenecks like trimming waste can slow output, increase costs, and create unnecessary housekeeping problems. With a Eurovac central vacuum system and the right discharge technology, Glacier Technology helped this customer streamline operations, reduce manual workloads, and maintain a clean, compliant workspace.

If your facility is facing similar waste handling, dust, or collection challenges, Glacier Technology can design and install a custom vacuum or air system that keeps your process running smoothly. Contact us to discuss your application.